D&D Automation was contracted by Daifuku Webb to provide controls engineering for a new Power & Free ‘doors off’ system for General Motors Canada at the CAMI Assembly plant. The new doors system needed to function alongside the existing production line for taking doors off of vehicles, building the doors, and then reattaching the doors to the same body.
D&D Automation provided electrical design and programming to the GM Global standard. Drawings were developed using EPLAN software for the new doors system. After an initial client review of the electrical design, D&D programmed three Allen Bradley GuardLogix PLC's to control each of the three chain conveyors. Each PLC controlled a separate section of the doors system, and these controllers needed to communicate with each other, the main line PLCs, and the plant's upper end system. Prior to the installation to take place over two weeks of summer shutdown, two of the PLCs were emulated to prove functionality and provide some debugging and commissioning time prior to the actual installation dates. By emulating the controllers and the system prior to installation, D&D was able to quickly commission the three PLCs during the shutdown.
D&D Automation was able to successfully commission the new door line system, without interfering with the existing production schedules of the plant. The use of Emulation software to simulate the system prior to shut down and installation greatly improved the efficiency of the commissioning during the shutdown. This opportunity allowed D&D to test and verify functionality of the programs, HMIs, and safety systems ahead of the schedule and reduced the number of hours required to commission the systems on site.
Success through preparation and planning!